TT453: BATTERY BEST PRACTICE INFORMATION
2020-03-31
Electrical

APPLIES TO

SYMPTOMS

Harley-Davidson’s AGM and Li-Ion 12 Volt Batteries

• Battery Maintenance
• Battery Testing Equipment
• Battery Charging Equipment

Reason for Revision
Refer to Table 1.
Table 1. Document History
Date

2020-03-31

2020-02-18

2018-08-15

2017-12-01

2017-11-16
2016-10-05

Revision Description
Updating references
Updated TESTING EQUIPMENT - AGM : GRX-3110HD Battery
Diagnostic Station, BEST PRACTICES THAT YIELD RESULTS * AGM : Battery Best Practices, CUSTOMER PERSONAL STORAGE
- LI-ION, BEST PRACTICES THAT YIELD RESULTS - LI-ION, FITMENT KITS - LI-ION
Added VEHICLE CHARGING SYSTEM - LI-ION, FITMENT KITS *
LI-ION : Table 11, WARRANTY - LI-ION
Bulletin restructure to cover Lithium-Ion (Li-ion) battery information
* Updated complete bulletin
Added TECHNICAL TIP GUIDE, ABSORBED GLASS MAT (AGM)
*
BATTERIES, LITHIUM-ION (LI-ION) 12 VOLT BATTERIES
Added BEST PRACTICES THAT YIELD RESULTS - AGM : Battery Best
Practices & Battery Testing Best Practices, STORAGE - AGM & Table
8, Figure 1
Update CHARGING EQUIPMENT - AGM : Table 6, STORAGE - AGM :
Battery Date Codes
Updated TESTING EQUIPMENT - AGM : GRX-3110HD Battery Diagnostic
Station, BATTERY MAINTENANCE - AGM : Overcharging & Other
Chargers & Undercharging, DEALERSHIP BATTERY MAINTENANCE
- AGM : Vehicles Demonstrating BOOM! Box Audio System, VEHICLE
TRANSPORT MODE (Security Systems Only) - AGM : Dealership Personnel
Updated TESTING EQUIPMENT - AGM : GRX-3110HD Battery Diagnostic
Station, BATTERY MAINTENANCE - AGM : Undercharging, DEALERSHIP BATTERY MAINTENANCE - AGM : Vehicles Not on Display &
Parts Inventory, CUSTOMER PERSONAL STORAGE - AGM & Table 5
Initial release

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TECHNICAL TIP GUIDE
Table 2. AGM - Technical Tip Bulletin Guide
ABSORBED GLASS MAT (AGM) BATTERIES
PURPOSE FOR TECH TIP
*
Operational Vehicles
TESTING EQUIPMENT - AGM
*
Non-operational
Vehicles Demonstrating BOOM! Box
*
GRX-3110HD Battery Diagnostic Station
*
Audio System
*
Fluke Digital Multimeter
*
Parts Inventory
CHARGING EQUIPMENT - AGM
CUSTOMER PERSONAL STORAGE - AGM
VEHICLE TRANSPORT MODE (Security SysINITIAL BATTERY CHECK - AGM
tems Only) - AGM
BATTERY MAINTENANCE - AGM
*
Dealership Personnel
BEST PRACTICES THAT YIELD RESULTS *
Overcharging
AGM
*
Other Chargers
*
Battery Best Practices
*
Undercharging
*
Battery Testing Best Practices
DEALERSHIP BATTERY MAINTENANCE STORAGE - AGM
AGM
*
Vehicles Not on Display
*
Battery Stocking and Sales
*
Vehicles on Display
*
Battery Date Codes
Table 3. Li-Ion - Technical Tip Bulletin Guide
LITHIUM-ION (LI-ION) 12 VOLT BATTERIES
TESTING EQUIPMENT - LI-ION
*
Parts Inventory
*
Fluke Digital Multimeter
CUSTOMER PERSONAL STORAGE - LI-ION
VEHICLE TRANSPORT MODE (Security SysCHARGING EQUIPMENT - LI-ION
tems Only) - LI-ION
VEHICLE CHARGING SYSTEM - LI-ION
*
Dealership Personnel
INITIAL BATTERY CHECK - LI-ION
FITMENT KITS - LI-ION
BEST PRACTICES THAT YIELD RESULTS BATTERY MAINTENANCE - LI-ION
LI-ION
DEALERSHIP BATTERY MAINTENANCE - LI*
Battery Best Practices
ION
*
Non-operational
*
Battery Testing Best Practices
Vehicles Demonstrating BOOM! Box
*
WARRANTY - LI-ION
Audio System

PURPOSE FOR TECH TIP
AGM Batteries: Tech Tip TT453 combines all battery, testing and charging information from
Service Bulletins M1089, M1089A, M1290, M1329, M1391, M1404 and M1418 and Tech Tips
TT342 and TT440 into one document. This also updates procedures and equipment to maintain,
test or charge all Absorbed Glass Mat (AGM) batteries.
Li-Ion Batteries: To explain the benefits and clarify the usage of the Lithium LiFe batteries.

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ABSORBED GLASS MAT (AGM) BATTERIES
TESTING EQUIPMENT - AGM
GRX-3110HD Battery Diagnostic Station
The HD BATTERY DIAGNOSTIC STATION (PART NUMBER: GRX-3110HD) can perform a
complete diagnostic recharging and evaluation routine within 3 h. Read the instruction manual
to perform battery testing. To download a copy of the GRX-3110 instruction manual in Portable
Document Format (PDF), login to H-Dnet and search for GRX-3110 instruction manual.
GRX-3110HD is primarily a diagnostic tool and not recommended to provide a long-term charge.
It is important that the station has the latest software revision installed to ensure that the station
performs the proper diagnostic tests. To verify for the latest version, navigate the following steps
on the GRX-3110:
Push RIGHT ARROW to view PRINT/VIEW > SELECT > Push RIGHT ARROW to view
VERSION INFO > SELECT
Verify current update on Service Bulletin M1391A: MIDTRONICS GRX-3110 SOFTWARE UPDATE
. This service bulletin contains the current update and instructions on how to install that update.

NOTE
Login into Service Information Portal (SIP) through Google Chrome to view link.
• M1391A
Severely discharged batteries no longer need to be jump-charged to begin charging. The
GRX-3110 can test and charge batteries at any beginning charge state. If the GRX-3110
determines the battery is healthy enough to accept a charge, it will begin the charging and testing
session which may take up to 3 h. During this session, the battery is tested a number of times.
When the session is complete, a report displaying the test results including battery replacement
indicator, charging results, state of health and a generated warranty code are available. This
information can be printed at the end of the session or later if needed. However, all data will be
overwritten when a new session is started.
If the battery voltage displayed on the final report is less than 12.5 V, continue to charge the
battery until 100% charge is achieved before placing it in service. This "top-off" charging can be
done using any Harley-Davidson approved charger. See Table 5 and Table 6 for list.

Fluke Digital Multimeter
The Digital Volt Ohm Meter (DVOM) is a hand-held device useful for basic fault finding and field
service work or a bench instrument which can measure to a very high degree of accuracy.
The Fluke 78 and 88 have been discontinued but will still work for all functions needed in testing
electrical circuitry. Fluke has replaced these models with the Fluke 789. See Table 4.

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Table 4. Digital Multimeters
Model

Part No.
HD-39978
HD-39978
HD-48650-20

Fluke 78
Fluke 88
Fluke 789

State
Discontinued
Discontinued
Offered

CHARGING EQUIPMENT - AGM
The selection of charging equipment can vary depending on the application. Harley-Davidson
recommends the following battery chargers. See Table 5 and Table 6.
Table 5. Harley-Davidson Chargers
Description
Part Number
SuperSmart
(North and South 66000038
750 mA
America,
SuperSmart
except Argentina) 66000004
800 mA
Global 1.25 AMP
66000033
(All, except Japan)
Global 1.25 AMP (Japan)
66000034
Global 5 AMP (Western Hem.)
66000041
Global 5 AMP (Europe)
66000042
Global 5 AMP (U.K.)
66000043
Global 5 AMP (Australia)
66000044

Description

Part Number

Global 5 AMP (Japan)

66000045

2-Bank Multi-Output

99829-09

4-Bank Multi-Output

99847-09

Waterproof 800 mA (Europe)
Waterproof 800 mA (U.K.)
Waterproof 800 mA (Australia)
Waterproof 800 mA (Japan)

99814-09
99816-09
99819-09
99820-09

Table 6. Deltran Chargers
Description
10-Bank 2 AMP

HD Part Number
66000040

Deltran Identification
021-0134

INITIAL BATTERY CHECK - AGM
Test initial battery voltage within 10 days of receipt. This applies to batteries in vehicles and
replacement parts inventory.

NOTE
When battery is out of vehicle, testing is done directly across the positive and negative battery
terminals.
1. Test voltage using a DVOM between main fuse [5B] terminal A and ground. If voltage is greater
than or equal to 12.5 V, voltage is within normal specifications. Charge as needed to keep
voltage above 12.5 V.
2. If voltage is less than 12.5 V, test battery with HD BATTERY DIAGNOSTIC STATION (PART
NUMBER: GRX-3110HD), follow instructions on station and on print out.

BATTERY MAINTENANCE - AGM
When a battery is received, whether P&A or in a new vehicle, follow these guidelines. It is the
dealership's responsibility to maintain new batteries above 12.5 V after initial battery check. Do
not call Technical Service for warranty authorization on batteries not properly maintained at the
dealership.

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Overcharging
AGM type batteries are filled with the proper amount of electrolyte and then sealed. If a charger
reaches too high a charge voltage (14.6 V or above), the water in the electrolyte will begin to
evaporate. This water vapor is released through a one-way relief valve on the top of the battery
case. Since the AGM battery is permanently sealed, the water cannot be replenished and the
battery becomes permanently low on electrolyte. This can result in loss of performance and
eventual battery failure. A sealed battery with concave sides is an example of one that has been
overcharged and has lost electrolyte. Overcharging with chargers designed for automotive use
is a major cause of battery failure.

Other Chargers
The only approved chargers for Harley-Davidson AGM batteries are the Harley-Davidson chargers
dated after 2010 and Deltran chargers listed in Table 5 or Table 6. Other chargers can allow the
battery voltage to climb over 14.6 V during charging causing the electrolyte in the battery to
evaporate, resulting in loss of performance and eventual battery failure.

Undercharging
If a battery charger does not bring the battery to a full charge, several problems can occur:
• The rated battery capacity will not be reached and the charging system may not bring the
battery to a full charge, especially in those instances where customers take short rides or ride
slowly with their electrical accessories on.
• If the vehicle is stored in a cold climate, an undercharged battery can freeze and crack.
• If the vehicle is stored in a hot climate 25 °C (77 °F) or warmer, the battery will self discharge
at a higher rate.
• A battery that sits in an undercharged state for a long period of time will sulfate. Sulfate hardens
on the battery plates preventing proper recharge. A sulfated battery is not serviceable and must
be discarded.
• Harley-Davidson and Deltran battery chargers incorporate a protection circuit that does not
allow charging if the battery is below 5 V. If you encounter a very low battery, it can be connected
to the GRX-3110HD.

DEALERSHIP BATTERY MAINTENANCE - AGM
Vehicles Not on Display
1. Remove main fuse when vehicle is stored.

NOTE
• All batteries are to be tested monthly.
• The battery discharges faster when the main fuse is installed. With the main fuse removed, a
100% charged battery drops to 12.5 V in approximately five months.
2. Test battery voltage. If voltage is approximately 12.5 V, charge battery using one of the
chargers in Table 5 or Table 6 until the charger indicates the battery is fully charged (12.7 V
or greater).
3. If voltage is less than 12.5 V, test battery with HD BATTERY DIAGNOSTIC STATION (PART
NUMBER: GRX-3110HD), follow instructions on station and on print out.

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4. If battery voltage drops below 12.5 V two months in a row, do the following:
a. Verify main fuse is removed. Remove if necessary.
b. Perform a milliampere draw test. See the Electrical Diagnostic Manual (EDM) for that vehicles
platform. Repair if necessary.
c. If main fuse is removed and draw test passed, file a warranty claim on battery.

Vehicles on Display
NOTE
Operational vehicles have the main fuse installed and keyed ignitions unlocked.
Non-operational vehicles have the main fuse removed.
Operational vehicles on display should have a battery charger installed, every other night. Vehicles
that have higher traffic or are displayed outside in 25 °C (77.0 °F) or greater should be charged
nightly.

Operational Vehicles
1. Remove battery charger from the vehicle. Turn ignition ON for one minute to remove surface
charge from battery, then turn ignition OFF.
2. Test battery voltage. If charging procedure above was followed and battery voltage is less
than 12.5 V, test battery with the GRX-3110, follow instructions on station and on print out.

Non-operational
1. Test battery voltage. If voltage is approximately 12.5 V, charge battery using one of the
chargers in Table 5 or Table 6 until the charger indicates the battery is fully charged (12.7 V
or greater).
2. If voltage is less than 12.5 V, test battery with the GRX-3110, follow instructions on station
and on print out.
3. If battery voltage drops below 12.5 V two months in a row, do the following:
a. Verify that main fuse is removed. Remove if necessary.
b. Perform a milliampere draw test. See the Electrical Diagnostic Manual (EDM) for that vehicles
platform. Repair if necessary.
c. If main fuse is removed and draws test passed, file a warranty claim on battery.

Vehicles Demonstrating BOOM! Box Audio System
The vehicle that is being used to demonstrate BOOM! should be tested the same as an operational
vehicle, but must have a recommended charger installed at all times. The BOOM! system draws
an excessive amount of current on a vehicle that is not running. To compensate for that, a charging
source must be connected to the vehicle.

Parts Inventory
1. Have 1 or 2 of each battery type on an Harley-Davidson approved charging station ready for
retail. Rotation of first in first out batteries to replace the topped off battery when retailed.

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2. Test battery voltage. If voltage is approximately 12.5 V, charge battery using one of the
chargers in Table 5 or Table 6 until the charger indicates the battery is fully charged ( 12.7 V
or greater).
3. If voltage is less than 12.5 V, test battery with the GRX-3110HD, follow instructions on station
and on print out.

CUSTOMER PERSONAL STORAGE - AGM
Encourage the customer to purchase and use one of the battery chargers in Table 5 or Table 6.
The battery chargers work on conventional batteries as well as the AGM type batteries. The
recommended battery chargers are specifically designed for the new AGM type battery and
provide proper charging automatically. These chargers prevent both over-charging and
undercharging.

VEHICLE TRANSPORT MODE (Security Systems Only) - AGM
Transport Mode arms the security system with motion detection disabled for one ignition cycle:
This allows movement of the vehicle in an armed state.
If the vehicle is being transported and was not placed in Transport Mode, the security alarm
activates due to motion detection. This will eventually drain the battery.

Dealership Personnel
During a new vehicle purchase, the person familiarizing the customer with the vehicle needs to
explain Transport Mode.
Upon delivery:
• Use Transport Mode if the vehicle is being transported.
• Ensure the person delivering the vehicle informs and demonstrates to the customer, the
operation of Transport Mode.
• Make sure that the customer is aware that the battery is fully charged at the time of delivery to
12.7 V or higher.
Other items to consider: Training material to review.
• Battery Fact and Best Practices course 1542 is available through HDU online.
• Shop Talk issue five of 2015 has more information on battery care and products.

BEST PRACTICES THAT YIELD RESULTS - AGM
Battery Best Practices
• Use a recommended battery charger/tender on vehicles whenever possible.
• The electrical system on early model vehicles typically only required the removal of the main
fuse to disconnect power to the motorcycle. Compared to the later models, the electrical systems
are more complex and sometimes need extra steps to deactivate all modules before removing
the main fuse. See the appropriate service manual for the correct power disconnect procedure.

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• Advise the customer that they include a battery charger with the purchase of their new vehicle
and make it part of the sale or offer them a special promotion. This is an opportunity to educate
the customer and encourage the use of a battery charger. For 2017, all models except V-Rods
have a battery charger connection incorporated into the vehicles harness. For pre 2017 models
and V-Rods, a charging harness is available separately for installation.
• Anytime a vehicle experiences an extended period of non-use, such as storage, connect a
battery tender to maintain battery charge. Verify the battery is fully charged before putting it
back in service. If the voltage is low, perform a battery test using the HD BATTERY
DIAGNOSTIC STATION (PART NUMBER: GRX-3110HD), follow instructions on station and